Increased durability welding torch assembly and components

ABSTRACT

A welding gun assembly having a connection between a diffuser and the inner gun tube which provides increased strength between the diffuser and the gun tube to prevent inadvertent damage to the welding torch and upstream components. The diffuser comprises an engagement portion which engages with, and overlaps, at least a part of a sturdier portion of the inner gun tube. This engagement provides a stronger and more stable connection between the gun tube and the diffuser.

PRIORITY

The present application is a continuation of and claims priority to U.S.patent application Ser. 14/589,226, filed on Jan. 5, 2015, which claimspriority to U.S. Provisional Patent Application No. 61/924,532, filed onJan. 7, 2014, both of which are incorporated herein by reference intheir entirety.

TECHNICAL FIELD

Devices, systems, and methods consistent with the invention relate towelding, and more specifically to devices, systems and methods forproviding an increased durability welding torch and welding torchcomponents.

BACKGROUND

In typical GMAW and GTAW type welding operations a welding torch/gun isused to deliver the arc to the weld in both automatic, semi-automaticand manual welding operations. Often times the torch/gun is handledroughly or makes significant contact with the workpiece, which canseverely damage the torch/gun such that it cannot effectively be used.For example, in manual and semi-automatic operations, users tend to usethe torch like a hammer to chip off slag from the weld, while inautomatic/robotic welding operations there can be instances where thetorch impacts the workpiece, tooling, etc. These events can cause damageto the torch and torch components, and can be particularly damaging whenthe impact loads on the torch are lateral. These loads can tend to bendthe torch—specifically at the gooseneck portion of the torch, which canadversely affect the wire feeding, and other operations of the torch.

Further limitations and disadvantages of conventional, traditional, andproposed approaches will become apparent to one of skill in the art,through comparison of such approaches with embodiments of the presentinvention as set forth in the remainder of the present application withreference to the drawings.

BRIEF SUMMARY OF THE INVENTION

An exemplary embodiment of the present invention is a welding gunassembly having a connection between a diffuser and the inner gun tubewhich provides increased strength between the diffuser and the gun tubeto prevent inadvertent damage to the welding torch and upstreamcomponents. The diffuser comprises an engagement portion which engageswith, and overlaps, at least a part of a sturdier portion of the innergun tube. This engagement provides a stronger and more stable connectionbetween the gun tube and the diffuser.

Another exemplary embodiment of the present invention is a welding torchassembly that includes an inner gun tube and a diffuser disposeddownstream of the inner gun tube. The inner gun tube has a main bodyportion and a distal end portion disposed downstream of the main bodyportion. The distal end portion has a wall thickness smaller than thatof the main body portion. The inner gun tube further includes a steppedportion that extends radially from the outer surface of the distal endportion to the outer surface of the main body portion. The diffuserincludes a cavity disposed on its upstream side. In the cavity isdisposed the distal end portion of the inner gun tube, which is coupledto the diffuser. The diffuser further includes a locking portiondisposed on its upstream end. When the inner gun tube fully engages thediffuser, the stepped portion of the inner gun tube contacts the lockingportion of the diffuser.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and/or other aspects of the invention will be more apparent bydescribing in detail exemplary embodiments of the invention withreference to the accompanying drawings, in which:

FIG. 1 illustrates an exemplary embodiment of a portion of a welding gunassembly of the present invention;

FIG. 2 illustrates a diffuser and an inner gun tube of the embodimentshown in FIG. 1;

FIG. 3. Illustrates an asymmetric view of the diffuser of FIG. 1;

FIG. 4 illustrates another exemplary embodiment of a diffuser of thepresent invention; and

FIG. 5 illustrates another view of a torch assembly of the presentinvention.

DETAILED DESCRIPTION

Exemplary embodiments of the invention will now be described below byreference to the attached Figures. The described exemplary embodimentsare intended to assist the understanding of the invention, and are notintended to limit the scope of the invention in any way. Like referencenumerals refer to like elements throughout.

It should be understood that throughout the present application the useof the terms welding torch and welding gun are intended to beinterchangeable, as both terms are used by those of skill in the art todescribe the torch/gun assembly.

As previously discussed, torches can be damaged by various events,especially events involving high load impacts. In robotic applicationsthis can occur when the torch inadvertently is caused to impact theworkpiece. These impacts are especially damaging when the torch has agoose-neck portion. A goose-neck portion is located upstream from thedistal, working end of the torch and is typically a bend in the gun tubehaving an angle in the range of 20 to 60 degrees. It is at the area ofthe bend that many instances of damage occur. Specifically, because ofthe pre-existing bend in the torch this area is more susceptible toadditional bending when loads are applied on the torch. When this bendarea is further bent due to external loads it can severely impede thepassing of a consumable through the gun tube. In some extreme instancesthe bend can be large enough to completely block the path of theconsumable and even shielding gas. Additionally, in known torches,because of the existing construction of torches, the connection betweenthe torch diffuser and the inner gun tube is such that a structural weakpoint exists in the structure or the inner gun tube which is also highlysusceptible to damage. Embodiments of the present invention addressthese issue and create a torch with increased integrity and usability.

FIG. 1 depicts the working end portion of an exemplary torch assembly100 of the present invention. For purposes of clarity the goose-neckportion of the gun tube is not shown in this figure. Furthermore,because the construction and operation of welding torches is generallyknown, the details of such construction and operation will not bediscussed in detail herein. As shown, the torch assembly 100 iscomprised of a number of components and is used to deliver both aconsumable and a shielding gas to the workpiece for a welding operation.The torch assembly 100 comprises an inner gun tube 101 having a mainbody portion (or upstream portion) 102 and a distal end portion 110,where the main body portion 102 has a thicker wall thickness than thedistal end portion 110, as shown. Covering the inner gun tube 101 is aninsulator 103 and an outer gun tube sheath 105. Threaded onto the distalend 110 of the gun tube 101 is a diffuser 120 which aids in properlydirecting and distributing the shielding gas for a welding operation.Coupled to the downstream end of the diffuser 120 is a contact tip 130,which is typically used to pass the welding current into the consumablewhich is passing though the center of the contact tip 130 during weldingThreaded onto the outside of the diffuser 120 is a nozzle 140, where thenozzle 140 is comprised of an inner nozzle component 141 which threadsonto the diffuser, as shown, an insulator portion 143 and an outernozzle portion 145. The insulator portion 143 electrically isolates theouter nozzle portion 145 from the electrically live components withinthe torch assembly 100. The nozzle 140 is used to direct the shieldinggas from the diffuser 120 to the distal end of the torch assembly 100and the workpiece for welding.

As shown in FIG. 1, the structural connection between the inner gun tube101 and the diffuser 120 is such that the connection has increasedstructural integrity. This connection is also shown in FIG. 2, omittingsome of the components described above, for clarity. As shown, thedistal end portion 110 of the inner gun tube 101 has a wall thicknesswhich is less than that of the wall thickness of the upstream portion102 (i.e. the main body portion) of the inner gun tube 101. The distalend portion 110 is inserted, and mechanically coupled (for example,using threads) into an end cavity 131 of the diffuser 120 with anupstream portion of the end cavity 131 having a larger inner diameterthan a downstream portion of the end cavity 131 as shown in FIG. 1. Thediffuser 120 also has a diffuser cavity 122 which is downstream of ashoulder portion 129, where the shoulder portion 129 separates the endcavity 131 of the diffuser 120 from the diffuser cavity 122. The innergun tube 101 also has a distal end 108 which, when fully inserted intothe end cavity 131 of the diffuser 120, creates a small gap between thedistal end 108 and the shoulder portion 129. In exemplary embodiments,this gap is very small, but the distal end 108 does not make contactwith the shoulder portion 129. Any contact between these surfaces cancompromise the proper construction and integrity of the torch assembly100. Also, as shown in each of FIGS. 1 and 2, the upstream end of thediffuser 120 comprises a locking portion (or stepped portion) 123 thatextends radially outwardly from the outer surface of the diffuser 120.When fully assembled, the locking portion 123 engages and locks with theinner gun tube 101 in such a way as to engage with the upstream portion102 of the gun tube 101. Specifically, the locking portion 123 engageswith the inner, gun tube 101 at its thicker portion. This is discussedfurther below.

As shown in the exemplary embodiments of FIGS. 1 and 2, the transitionbetween the upstream portion 102 and the distal end portion 110 of thegun tube 101 has a locking shoulder portion (or stepped portion) 107which radially extends from the outer wall of the distal end portion 110to the outer wall of the upstream portion 102 of the inner gun tube 101When fully assembled, the locking portion 123 of the diffuser 120engages with the locking shoulder portion 107 and the outer surface ofthe upstream portion 102. As can be seen in FIG. 2, the locking portion123 of the diffuser 120 surrounds the locking shoulder portion 107 ofthe inner gun tube 101 from radially outward of the locking shoulderportion 107. Specifically, the locking portion 123 comprises a shoulderengaging portion 125, which contacts the locking shoulder portion 107when the diffuser 120 is fully installed. Further, the locking portion123 comprises an extension portion 127 which extends along a length ofthe outer surface of the upstream portion 102 of the inner gun tube 101(or in a axial direction of the inner gun tube 101). The extensionportion 127, which defines the upstream portion of the end cavity 131having the larger inner diameter, comprises an interior surface 128which engages with the outer surface of the upstream portion 102. Inexemplary embodiments of the present invention, the engagement betweenthe interior surface 128 and the outer surface of the upstream portion102 is a friction fit type connection where at least some contact existsbetween the surfaces. If this connection is too loose then some of thestructural integrity improvements of the present invention may not befully realized. Further, in some exemplary embodiments, the transitionbetween the interior surface 128 and the shoulder engaging portion 125(i.e. inner corner portion of the stepped portion) is chamfered orradiused. This aids in reducing stress concentrations at this connectionpoint.

In exemplary embodiments of the present invention, the radial height (orradial thickness) of the shoulder portion 107 is in the range of 10 to20% of the outer diameter of the upper portion 102 of the inner gun tube101 at the connection between the diffuser 120 and the inner gun tube101. In other exemplary embodiments, the radial height is in the rangeof 10 to 15%. Such a radial height (distance between the outer surfaceof the distal end portion 110 and the outer surface of the upper portion102) provides sufficient structural stability, while ensuring thestructural integrity of the gun tube 101 remains. Further, in additionalexemplary embodiments, the length of the interior surface 128 is atleast as long, or longer than the radial height of the shoulder portion107. That is, the length of the interior surface 128 of the lockingportion 123 on the inner gun tube 101 is at least as long, or longerthan the height difference between the distal end portion 110 and theupstream portion 102 of the tube 101. In exemplary embodiments of thepresent invention, the interior surface 128 is longer than the shoulderportion 107 by a distance in the range of 0 to 45% of the lockingshoulder portion 107. In other exemplary embodiments of the presentinvention, the interior surface 128 is longer than the shoulder portion107 by a distance in the range of 20 to 45% of the height of the lockingshoulder portion 107. By having the interior surface 128 longer than theheight of the locking shoulder portion 107, a significant increase inbending strength is achieved between the diffuser 120 and inner gun tube101. However, if the length of the interior surface 128 becomes toolong, it will be difficult to ensure the desired fit between thecomponents to achieve the desired structural integrity.

With the connection structure described above, any inadvertent loads orforces placed on the nozzle/diffuser are directed directly to thethicker portion (i.e. upstream portion) 102 of the inner gun tube 101.Such a connection structure has not been previously used in gun/torchconstruction. In some known connection methodologies, the diffuser iscoupled only to a narrow portion of the inner gun tube. In such aconnection structure, any loads on the nozzle/diffuser are directed toonly a thinner portion of the gun tube, which can cause severe damage tothe gun tube—sometimes necessitating replacement. With the connectionstructure described herein, a construction is achieved whichsignificantly resists both sides loads and axial loads on the torch. Infact, torches constructed as described herein can sustain nearly doublethe impact loads than known torches without the need for significantthickness increases in the components. With the construction describedherein, forces and impact loads are more easily directed into the upperportion of the inner gun tube 101, thus making the construction morestable. FIG. 3 depicts an asymmetric view of the diffuser 120 describedabove.

Another exemplary embodiment of the present invention is shown in FIG.4. In this embodiment, the diffuser 120 further includes a break-awayrecess 200 on an outer surface of the diffuser 120. As shown in FIG. 4,this recess 200 may be disposed downstream of the end cavity 131 of thediffuser 120. The break-away recess 200 provides a weak point in thediffuser 120 such that when a force or a load is applied to the distalend of the torch, the diffuser 120 fails at the break-away recess 200.While this will destroy the diffuser, it can save any components of thewelding system upstream of the diffuser 120, and may save components atthe end of the torch, such as the nozzle components. That is, the recess200 is to be constructed such that when the torch assembly 100experiences an impact load or force above a threshold, the downstreamportion of the diffuser 120 (downstream of the recess 200) breaks awayfrom the upstream portion of the diffuser 120 which remains coupled tothe inner gun tube 101. Such a feature ensures that no upstreamcomponents, such as robot arms components or the goose-neck portion ofthe torch, etc. are damaged when an impact occurs. In exemplaryembodiments, the shape and depth of the recess is to be determined suchthat the optimal break-away conditions are achieved. For example, inexemplary embodiments, the break-away recess 200 has a depth which is inthe range of 35 to 65% of the wall thickness of the diffuser 120 at thepoint of the recess 200. Further, in exemplary embodiments, the recess200 may have a pointed, or narrow bottom surface to the recess (i.e.v-shaped groove) 200. This is depicted in FIG. 4, which shows the recess200 as triangular. Having such a shape aids in concentrating stresses atthe recess portion 200 and ensures that the diffuser 120 fails at thedesired location. Of course, the recess portion 200 can have othershapes so long as the desired break-away abilities are achieved.

FIG. 5 depicts a typical torch or gun assembly of the present inventionwith a goose-neck portion 10 shown.

While the claimed subject matter of the present application has beendescribed with reference to certain embodiments, it will be understoodby those skilled in the art that various changes may be made andequivalents may be substituted without departing from the scope of theclaimed subject matter. In addition, many modifications may be made toadapt a particular situation or material to the teachings of the claimedsubject matter without departing from its scope. Therefore, it isintended that the claimed subject matter not be limited to theparticular embodiment disclosed, but that the claimed subject matterwill include all embodiments falling within the scope of the appendedclaims.

What is claimed is:
 1. A diffuser for a welding torch assembly,comprising: a cavity disposed on an upstream side of the diffuser, thecavity having: a first portion that is configured to accept therein adistal end portion of an inner gun tube, and a second portion that isconfigured to accept therein a portion of a main body portion of theinner gun tube; and a stepped portion disposed on the upstream side ofthe diffuser, extending radially outwardly from the first portion to thesecond portion, wherein the stepped portion is configured to contact asecond stepped portion of the inner gun tube when the inner gun tubefully engages the diffuser, and wherein a downstream side of thediffuser is configured to couple to a contact tip to pass a weldingcurrent into a consumable welding wire received by the diffuser from theinner gun tube.
 2. The diffuser of claim 1, wherein the cavity isconfigured to accept the distal end portion of the inner gun tube by wayof a threaded connection.
 3. The diffuser of claim 1, further comprisinga shoulder portion extending radially at a downstream end of the cavity,wherein a gap forms between the distal end portion of the inner gun tubeand the shoulder portion when the inner gun tube fully engages thediffuser.
 4. The diffuser of claim 1, further comprising a break-awayrecess on an outer surface of the diffuser configured to provide a weakpoint in the diffuser where, when a force or load being above athreshold is applied to the diffuser, the diffuser fails at thebreak-away recess.
 5. The diffuser of claim 4, wherein the break-awayrecess is a v-shaped groove.
 6. The diffuser of claim 1, wherein theupstream side of the diffuser is configured to receive a shielding gasfrom the inner gun tube during a welding operation.
 7. The diffuser ofclaim 6, wherein the downstream side of the diffuser is configured todirect and distribute the shielding gas received by the upstream side ofthe diffuser during the welding operation.
 8. The diffuser of claim 1,further comprising an axial extension portion extending in an axialdirection to define the second portion of the cavity.
 9. The diffuser ofclaim 8, wherein an inner surface of the axial extension portion isconfigured to engage with an outer surface of the main body portion ofthe inner gun tube by way of a friction fit.
 10. The diffuser of claim8, wherein the stepped portion includes an inner corner portionconfigured as being chamfered or radiused.
 11. A diffuser for a weldingtorch assembly, comprising: a downstream side configured to couple to acontact tip to pass a welding current into a consumable welding wirereceived by the diffuser from an inner gun tube; and an upstream sideincluding: a cavity configured to couple to a distal end portion of theinner gun tube, and a locking portion including an inner surfaceconfigured to engage with an outer surface of a main body portion of theinner gun tube, wherein the locking portion is configured to contact astepped portion of the inner gun tube when the inner gun tube fullyengages the diffuser, where the stepped portion of the inner gun tubeextends radially from an outer surface of a distal end portion of theinner gun tube to an outer surface of the main body portion of the innergun tube,
 12. The diffuser of claim 11, wherein the inner surface of thelocking portion has an axial length that is equal to or longer than aradial thickness of the stepped portion of the inner gun tube.
 13. Thediffuser of claim 11, wherein the cavity is configured to accept thedistal end portion of the inner gun tube by way of a threadedconnection.
 14. The diffuser of claim 11, further comprising a shoulderportion extending radially at a downstream end of the cavity, wherein agap forms between the distal end portion of the inner gun tube and theshoulder portion when the inner gun tube fully engages the diffuser. 15.The diffuser of claim 11, further comprising a break-away recess on anouter surface of the diffuser, wherein the break-away recess is disposeddownstream of the cavity of the diffuser.
 16. The diffuser of claim 15,wherein the break-away recess is a v-shaped groove.
 17. The diffuser ofclaim 11, wherein the upstream side of the diffuser is configured toreceive a shielding gas from the inner gun tube during a weldingoperation.
 18. The diffuser of claim 17, wherein the downstream side ofthe diffuser is configured to direct and distribute the shielding gasreceived by the upstream side of the diffuser during the weldingoperation.
 19. The diffuser of claim 18, further comprising an outersurface configured to engage with a nozzle for directing the shieldinggas from the diffuser toward a workpiece during the welding operation.20. The diffuser of claim 19, wherein the outer surface of the diffuseris configured to engage with the nozzle by way of a threaded connection.